Multilayer, composite, fleece material and a method for manufacturing a multilayer, composite, fleece material

Abstract

The invention relates to a multilayer, composite, fleece material having a core layer and at least one cover layer attached to the core layer, where the at least one cover layer is needled with the core layer such that fibers of the at least one cover layer protrude into the core layer. The multilayer, composite, fleece material is intended for use in the manufacture of interior panels of vehicles and to have improved mechanical properties, low thermal conductivity, very low tendency to produce emissions, and good acoustic properties when used for that purpose, as well as enable its inexpensive manufacture. The cover layer and the fibers protruding from the cover layer into the core layer are at least partially firmly bonded to the core layer, where the core layer contains amorphous, bicomponent fibers having a component with a lower melting point and a component with a higher melting point, and the at least one cover layer contains crystalline, bicomponent fibers having a component with a lower melting point and a component with a higher melting point. The invention also relates to a method for manufacturing a multilayer, composite, fleece material and a method for manufacturing a molded component, for example, an automobile headlining, from the composite, fleece material.

1. A multilayer, composite, fleece material having a core layer and at least one cover layer attached to the core layer, where the at least one cover layer is needled with the core layer such that fibers of the at least one cover layer protrude into the core layer, characterized in that the cover layer and the fibers protruding from the cover layer into the core layer are at least partially firmly bonded to the core layer, where the core layer contains amorphous sheath, bicomponent fibers having a component with a lower melting point and a component with a higher melting point, and the at least one cover layer contains crystalline sheath, bicomponent fibers having a component with a lower melting point and a component with a higher melting point. 
     
     
       2. A composite, fleece material according to  claim 1 , characterized in that at least one cover layer is arranged on either side of the core layer. 
     
     
       3. A composite, fleece material according to  claim 1 , characterized in that the firmly bonded joint between the core layer and the at least one cover layer and the fibers protruding from the at least one cover layer into the core layer originate from a heat-treatment process. 
     
     
       4. A composite, fleece material according to  claim 1 , characterized in that the lower-melting-point components of the bicomponent fibers at least partially envelop neighboring fibers of the core layer and/or the at least one cover layer. 
     
     
       5. A composite, fleece material according to  claim 1 , characterized in that the thickness of the core layer exceeds the thickness of the at least one cover layer. 
     
     
       6. A composite, fleece material according to  claim 1 , characterized in that the weight per unit area of the core layer exceeds that of the at least one cover layer. 
     
     
       7. A composite, fleece material according to  claim 1 , characterized in that the weight per unit volume of the core layer is less than that of the at least one cover layer. 
     
     
       8. A composite, fleece material according to  claim 1 , characterized in that the weight per unit area of the core layer falls within the range 500 g/m 2 -800 g/m 2 . 
     
     
       9. A composite, fleece material according to  claim 1 , characterized in that the weight per unit area of the at least one cover layer falls within the range 150 g/m 2 -250 g/m 2 . 
     
     
       10. A composite, fleece material according to  claim 1 , characterized in that the core layer and/or the at least one cover layer contain PET-matrix fibers. 
     
     
       11. A composite, fleece material according to  claim 1 , characterized in that the core layer contains about 50% amorphous sheath, bicomponent fibers and about 50% PET-matrix fibers. 
     
     
       12. A composite, fleece material according to  claim 1 , characterized in that the at least one cover layer contains about 70% crystalline sheath, bicomponent fibers and about 30% PET-matrix fibers. 
     
     
       13. A composite, fleece material according to  claim 1 , characterized in that the melting point of the lower-melting-point component of the amorphous sheath, bicomponent fibers of the core layer is approximately 110° C. 
     
     
       14. A composite, fleece material according to  claim 1 , characterized in that the melting point of the lower-melting-point component of the crystalline sheath, bicomponent fibers of the at least one cover layer is approximately 165° C. 
     
     
       15. A composite, fleece material according to  claim 1 , characterized in that the amorphous sheath, bicomponent fibers have a linear density of about 4.4 dtex. 
     
     
       16. A composite, fleece material according to  claim 1 , characterized in that the crystalline sheath, bicomponent fibers have a linear density of about 7.0 dtex. 
     
     
       17. A composite, fleece material according to  claim 1 , characterized in that the insertion density of the needled, composite, fleece material per side falls within the range 80 insertions/cm 2 -130 insertions/cm 2 . 
     
     
       18. A composite, fleece material according to  claim 1 , characterized in that the core layer consists of a preneedled, fleece material. 
     
     
       19. A composite, fleece material according to  claim 18 , characterized in that the insertion density of the needled core layer falls within the range of 50 insertions/cm 2 -120 insertions/cm 2 . 
     
     
       20. A method for manufacturing a multilayer, composite, fleece material according to  claim 1 , characterized by the following steps: providing a core layer that, at least partly, contains amorphous sheath, bicomponent fibers having a lower-melting-point component and a higher-melting-point component, applying a cover layer that, at least partly, contains crystalline sheath, bicomponent fibers having a lower-melting-point component and a higher-melting-point component to at least one side of the core layer, needling the at least one cover layer onto the core layer, heating the needled layers to a temperature exceeding the melting points of the lower-melting-point components of the bicomponent fibers, and cooling the composite, fleece material. 
     
     
       21. A method according to  claim 20 , characterized in that the needled layers are heated to a temperature of about 185° C. 
     
     
       22. A method according to  claim 20 , characterized in that at least one cover layer is applied to either side of the core layer. 
     
     
       23. A method according to  claim 20 , characterized in that the core layer is needled prior to lamination of the composite, fleece material. 
     
     
       24. A method according to  claim 20 , characterized in that the at least one cover layer and the core layer are pressed together following heating. 
     
     
       25. A method according to  claim 20 , characterized in that the composite, fleece material is calendered following heating. 
     
     
       26. A method for manufacturing a formed component from a composite, fleece material according to  claim 1  characterized by the following steps: heating the composite, fleece material to a temperature of about 200° C., inserting the heated, composite, fleece material into a thermostated mold, and molding the composite, fleece material.